Composite fabric with adsorbent polymer material

ABSTRACT

In some aspects, the disclosure relates to composite fabric assembly comprising a fabric substrate including a surface and a layer adhered to or impregnated into the surface of the fabric substrate, the layer including polymer resin particles, wherein polymer resin particles are configured to adsorb at least one of an organic compound, inorganic compound, or chemicals.

This application claims the benefit of U.S. Provisional Application No. 61/704,258, filed Sep. 21, 2012, the entire content of which is incorporated herein by reference.

TECHNICAL FIELD

In some examples, the disclosure relates to composite fabric assemblies with adsorbent material.

SUMMARY

Composite fabric assemblies including polymer resin particles in a layer deposited on the surface of a fabric substrate, where the polymer resin particles are configured to adsorb at least one of an organic compound and/or chemicals, are described. The layer including polymer resin particles may be substantially continuous over the surface of the substrate or may be a discontinuous layer, e.g., a layer including a plurality of discrete deposits of the polymer resin particles separated by gaps on the surface of the fabric substrate.

In some examples, the disclosure relates to a composite fabric assembly comprising a fabric substrate including a surface; and a layer adhered to or impregnated into the surface of the fabric substrate, the layer including polymer resin particles, wherein the polymer resin particles are configured to adsorb at least one of an organic compound, inorganic compound, or chemicals.

In other examples, the disclosure relates to a method a composite fabric assembly, the method comprising depositing a layer on a surface of a fabric substrate, wherein the layer is adhered to or is impregnated into the surface of the fabric substrate, wherein the layer includes polymer resin particles, wherein the polymer resin particles are configured to adsorb at least one of an organic compound, inorganic compound, or chemicals.

The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a conceptual diagram illustrating a perspective view of an example fabric assembly in accordance with the disclosure.

FIG. 2 is a diagram illustrating a cross-sectional view of the example fabric assembly of FIG. 1.

FIG. 3 is a conceptual diagram illustrating a plan view of another example fabric assembly in accordance with the disclosure.

FIG. 4 is a diagram illustrating a cross-sectional view of the example fabric assembly of FIG. 3 along line A-A.

DETAILED DESCRIPTION

As described above, in some examples, the disclosure relates to fabric assemblies including polymer resin particles in a layer deposited on the surface of a fabric substrate, where the polymer resin particles are configured to adsorb compounds, e.g., organic compounds and/or inorganic compounds, and/or one or more chemicals.

Such fabric assemblies may be utilized for a variety of applications. For example, the assemblies may be used for human odor adsorbing apparel, e.g., as used in hunting applications to reduce the scent released by hunter. In such cases, the polymer resin particles of the layer deposited on the fabric substrate may be selected to adsorb the volatile organic compounds emitted by the human body that result in human odor. In the case of adsorption of odor, the polymer resin particles may be configured to adsorb short chain carboxylic fatty acids, such as, e.g., butyric, isovaleric, methyl hexanoic, and/or trans hexanoic acid.

However, the fabric assemblies described herein are not limited to human odor adsorbing assemblies but may include other applications, such as assemblies including polymer resin particles configured to adsorb one or chemicals, e.g., for industrial safety or biohazard applications. Moreover, other odors applications for example fabric assemblies besides that of hunting apparel may include, for example, fabric for use in pet bedding, athletic apparel, and other applications in which odor adsorption is desirable. For ease of illustration, examples of the disclosure are primarily described with regard to apparel used for hunting applications. However, examples of the disclosure are not limited as such.

FIG. 1 is a conceptual diagram illustrating a perspective view of an example fabric assembly 10 in accordance with an example of the disclosure. FIG. 2 is a diagram illustrating a cross-sectional view of the example fabric assembly 10 of FIG. 1. As shown, fabric assembly 10 includes fabric substrate 12 with layer 14 deposited on the surface of substrate 12. Layer 14 includes polymer resin particles (not shown individually in layer 14) which are configured to adsorb at least one of organic compounds or chemicals.

Fabric substrate 12 may be a substrate that is permeable to air, thereby be susceptible to volatile organic/inorganic compounds and/or chemicals to permeate through substrate 12, and may have any suitable thickness for the intended application. In some examples, fabric substrate 12 may be a knit and synthetic (polyester versus cotton) fabric. The face fabrics or face laminations can be a non-woven scrim merely for protection of adsorbent layer 14, to camouflage fabrics which could be knit or woven, polyester, nylon, cotton, and the like. While fabric substrate 12 is shown as a single fabric layer, in some examples, assembly 10 may include one or more additional layers, e.g., other layers such as waterproof or windproof membrane layers. Layer 12 or other layers of assembly 10 may be subject to one or more treatments, such as, as moisture wicking, antimicrobial, water resistance, stain resistance, and the like.

The polymer resin particles in layer 14 may be selected based on the compound/chemical desired to be adsorbed by assembly 10, e.g., based on the desired use of the material. As noted above, in some examples, the polymer resin particles of the layer deposited on the fabric substrate may be selected to adsorb the volatile organic compounds emitted by the human body that result in human odor, e.g., in hunting apparel applications. For example, for hunting garments, odors of interest would include but is not limited to: odors put off by the human including breath odor, axillary odor from underarms, groin, and the like; perfume and other toiletry-type odors; and environmental odors such as household, cooking, automotive, pet, and the like. Many of the human-type odors are that the polymer resin particle are configured to adsorb may be represented by those most characteristic and typical of the smell of sweaty body odor (axillary), e.g., short chain carboxylic fatty acids such as butyric, isovaleric, methyl hexanoic, and trans hexanoic acid. Such examples may be highly polar, high molecular weight compounds. However, the polymer resin adsorbents may be manufactured with affinity for various compounds, chemicals, and/or charged partials. Thus, by altering the adsorbent, one can make fabric assembly 10 very selective and can be applied to numerous markets applications. In some examples, characteristics of adsorbent polymer material include a relatively high amount of surface area. In some examples, the polymer resin particles may have a surface of about 900-1000 m²/gram, and in some cases even higher. Further, an adsorbent polymer material may have relatively good porosity (pore size distribution).

In some examples, the polymer resin particular used for odor adsorption are more hydrophobic than activated carbon. It therefore adsorbs less moisture and may be more effective in adsorbing volatile organics and odors in humid environment, particularly the kind of conditions encountered by hunters during warm or early season hunts, and especially as relates to the underarm and groin areas. In other cases, it may be desirable for the polymer resin particular used for odor adsorption to be more hydrophilic than activated carbon. Further, the polymer resin particular used for odor adsorption may improve the wicking properties of the composite fabric assembly, e.g., as compared to the wicking properties of the fabric substrate alone.

In some examples, layer 14 may include polymer resin particles initially provided as beads, e.g., styrene and divinylbenzene beads, having a particle size greater than 200 microns, such as, e.g., 5,000 microns to 7,000 microns, which are subsequently ground down to a particle size that is less than 200 microns, such as, less than 100 microns or between 44 and 75 microns. Regardless of whether or not the particles are ground or otherwise derived from larger particles, some examples of the disclosure include layer 14 having adsorbent polymer resin particles with a particle size that is less than 200 microns, such as, less than 100 microns or between 44 and 75 microns. In this manner, the surface of the polymer resin particles may be increased, thereby increasing the adsorption by the particles, e.g., compared to those having a particle size between 5,000 microns and 7,000 microns.

Layer 14 may include one or more additive materials besides that of the polymer resin particles. For example, layer 14 may include a binder configured to adhere the polymer resin particles to the surface of substrate 12. Binder materials may include a powdered EVA type or a polyamide resin-based adhesive, or a water-soluble acrylic type adhesive. The polymer resin particles in layer 14 may be mixed with the binder material then applied to the surface of substrate 12. The binder material may hold the polymer resin particles to the fabric in a manner that leaves a majority of the particles exposed to adsorb odor, chemicals, and other compounds of interest. As will be described below, two types of examples methods for applying layer 14 to fabric 12 include 1) substantially continuous spray coating, similar to spray painting a surface, and 2) interrupted/spot application, much like a dot pattern. Imprasil or Impranil (hot melt) may be one example type of binder used in such a dot pattern configuration or other discontinuous layer examples as described further below. Other example additive materials for layer 14 include a surfactant, or a suspension agent. Other examples additives may also include materials that cause the assembly to be more hydrophobic or hydrophilic, and/or increase the wicking properties of the assembly.

The order in which the components in layer 14 are added or mixed may also be important in some cases. In some examples, the composition of layer 14 includes greater than 60 wt. % of the polymer resin particles, such as, e.g., about 67 wt. % to about 72 wt. %. In some examples, the amount of binder material in layer 14 may be less than 40%, such as, e.g., about 28 wt. % to about 32 wt. %. Layer 14 may have any suitable thickness. In some examples, the thickness of layer 14 is greater than 0.025 millimeters. The thickness of layer 14 for heavier loaded fabrics may have a greater thickness compared to lighter loaded fabric applications.

FIG. 3 is a conceptual diagram illustrating a plan view of another example fabric assembly 18 in accordance with an example of the disclosure. FIG. 4 is a diagram illustrating cross-sectional view of the example fabric assembly 18 of FIG. 3 along line A-A. As shown, fabric assembly 18 includes fabric substrate 12 and adsorbent layer 16. Fabric substrate 12 may be substantially the same or similar to that of substrate 12 described above with regard to fabric assembly 10. Adsorbent layer 16 may be substantially the same or similar to that of layer 14 described above with regard to assembly 10.

However, as shown FIGS. 3 and 4, unlike that of layer 12 which forms a substantially continuous layer over substrate 12, layer 16 forms only a discontinuous layer on the surface of substrate 12. For example, in the example of FIGS. 3 and 4, layer 16 is formed by a plurality of discrete deposits 16 of polymer resin particles separated by gaps on the surface of the fabric substrate. Only a single discrete deposit 16 is labeled in FIGS. 3 and 4 for clarity. The discrete deposits of the polymer resin particles 16 may be separated by gaps on the surface of the fabric substrate to allow for portions of the surface of substrate 12 to not be covered by adsorbent layer 16. The discrete deposits may be arranged according to a predetermined pattern, such as, a dot matrix, or may be randomly distributed onto the surface of substrate 12. In some examples, the use of a discontinuous adsorbent layer rather than a substantially continuous layer, may allow for good coverage of the adsorbent material with small gaps between the areas of absorbent application. Such gaps may allow fabric substrate 12 to flex, move, and drape at or near its normal non-coated state. In some examples, such flexibility may be critical on light weight clothing.

Any suitable method may be used to make fabric assembly 10 with a substantially continuous adsorbent layer and fabric assembly 18 with a discontinuous adsorbent layer. As noted above, a substantially continuous adsorbent layer may be formed by substantially continuous spray coating, similar to spray painting a surface. A discontinuous adsorption layer may be applied using an interrupted or spot application of the layer material including polymer resin particles. In some examples, a discontinuous adsorption layer may be formed by screen printing the polymer material onto the surface of a fabric substrate. Another suitable example application technique may include flood coating of the material on the surface of the fabric substrate.

In some examples, the continuous adsorbent layer assemblies and discontinuous adsorbent layer assemblies described herein may have a single layer construction. This means there is only a fabric with the applied absorbent. In such examples, the absorbent is fully exposed and is not covered with a second layer making it a more efficient absorbent construction. Multilayer construction may be utilized in other examples.

Some examples described herein may allow for one or more advantages. For example, by utilizing a relatively small particle size (e.g., less than about 200 microns) for the adsorptive polymer resin, the adsorbent material may be deposited as a substantially continuous coating on the fabric allowing for a truly continuous layer of adsorbent, with relatively high protection and adsorption properties. Additionally or alternatively, the absorbent to be applied by spraying and other deposition methods. Smaller particle size may allow for better adhesion to the fabric thus offering better wear characteristics. Also, smaller particle size may allow for maximum garment comfort, e.g., due to a lighter weight, thinner fabric cross-section, flexibility, and the like. Further, smaller particle size can lead to greater surface area and greater adsorption.

Another benefit of some examples of the application include those in which a fabric assembly for use in apparel does not require a protective layer between the skin of a wearer and the adsorbent layer, e.g., compared to those fabric assemblies utilizing carbon as an adsorbed layer. In particular, polymer resin particles may be relatively clean compared to a carbon material which may rub off or otherwise deposit carbon material onto the skin of a wearer without that of a protective layer. Moreover, since the polymer resin particles may be impregnated or adhered to the surface of the fabric substrate, a second layer of fabric, such as a hung layer, may not be required to prevent separation of the polymer resin particles from the fabric due to the direct contact by the wearer with the polymer resin particles.

EXAMPLE

The level of adsorption by a fabric assembly such as that described herein may be quantified using various techniques. In one example, one may weigh a known sized swatch of the material from a fabric assembly including an adsorption layer in a pristine condition, and then subject the swatch to an odorant. The swatch may then be weighed at various intervals to determine the amount of odorant it is capable of adsorbing over time. These weights may be compared to other known adsorbents or to a material such as a plain fabric without adsorbent that will adsorb some odor usually but very little. The results are usually expressed in terms of milligrams of odorant adsorbed, or sometimes as milligrams of odorant adsorbed per gram of fabric, so that it accounts for the weight and thickness of the fabric surrounding the adsorbent, as these fabrics generally have some adsorption capacity of their own. In example fabric assemblies constructed in accordance with one or more examples described herein, adsorption rates of 20-35 milligrams/gram at 24 hours and overall adsorption (not taking into account the weight of the overall fabric) of 40-60 milligrams have been observed.

Various embodiments of the disclosure have been described. These and other embodiments are within the scope of the following claims. 

1. A composite fabric assembly comprising: a fabric substrate including a surface; and a layer adhered to or impregnated into the surface of the fabric substrate, the layer including polymer resin particles, wherein the polymer resin particles are configured to adsorb at least one of an organic compound, inorganic compound, or chemicals.
 2. The assembly of claim 1, wherein the layer including polymer resin particles comprises a substantially continuous layer over the surface of the fabric substrate.
 3. The assembly of claim 1, wherein the layer including polymer resin particles comprises a discontinuous layer over the surface of the fabric substrate.
 4. The assembly of claim 3, wherein the discontinuous layer over the surface of the fabric substrate is defined by a plurality of discrete deposits of the polymer resin particles separated by gaps on the surface of the fabric substrate, and wherein the plurality of discrete deposits of the polymer resin particles separated by gaps on the surface of the fabric substrate are arranged according to a predetermined pattern.
 5. The assembly of claim 1, wherein the polymer resin particles exhibit a particle size less than approximately 200 microns.
 6. The assembly of claim 5, wherein the polymer resin particles exhibit a particle size less than approximately 100 microns.
 7. The assembly of claim 1, wherein the polymer resin particles adsorb body odor.
 8. The assembly of claim 7, wherein the polymer resin particles adsorb short chain carboxylic fatty acids.
 9. The assembly of claim 8, wherein the short chain carboxylic fatty acids include at least one of butyric, isovaleric, methyl hexanoic, and trans hexanoic acid.
 10. The assembly of claim 1, wherein the polymer resin particles are more hydrophobic than activated carbon.
 11. The assembly of claim 1, wherein the layer including polymer resin particles defines a thickness of at least 0.025 millimeters.
 12. The assembly of claim 1, wherein the layer including polymer resin particles includes a binder material to adhere the particles to the surface of the fabric.
 13. The assembly of claim 12, wherein the layer has greater than about 60 wt. % of the polymer resin particles.
 14. The assembly of claim 12, wherein the layer includes less than about 40 wt. % of binder material.
 15. A method of making a fabric assembly, the method comprising depositing a layer on a surface of a fabric substrate, wherein the layer is adhered to or is impregnated into the surface of the fabric substrate, wherein the layer includes polymer resin particles, wherein the polymer resin particles are configured to adsorb at least one of an organic compound or chemicals.
 16. The method of claim 15, wherein depositing the layer on the surface of the substrate comprises depositing the layer on the surface of the substrate via spray application, printing, or flood coating.
 17. The method of claim 16, wherein depositing the layer via printing comprises depositing the layer via screen printing.
 18. The method of claim 15, wherein the polymer resin particles adsorb body odor.
 19. The method of claim 19, wherein the polymer resin particles adsorb short chain carboxylic fatty acids. 